Apparatus for the manufacture of metal articles



Feb. 10, 1942. w, L, FADER, JR

APPARATUS FOR THE MANUFACTURE OF METAL ARTICLES Original Filed Oct. 16, 1939 3 Sheets-Sheet l INVENTOR 1/44; a! #4444 Feb. 10. 1942. w. FADER, JR

APPARATUS FOR THE MANUFACTURE OF METAL ARTICLES aw a w m. m /F/ f 2 m w. 4 m x A z fi x V 3 m M iv Z Y 9 5 *1 w M m 6 Feb. 10, 1942.

APPARATUS FOR THE MANUFACTURE OF METAL ARTICLES Original Filed 00$. 16, 1959 3 Sheets-Sheet 3 .Mll.

INVENTOR mam of a m Patented Feb. 10, 1942 TESL EFICE APPARATUS FOR THE MANUFACTURE OF METAL ARTICLES William L. Fader, Jr., Sewickley, Pa., assignor to Pittsburgh Forgings Company, a corporation of Delaware 8 Claims.

This invention relates to the manufacture of metal articles, particularly to articles that are shaped from bars or straps of steel, and consists in apparatus. The application for this patent is a division of my application Serial No. 299,600, filed October 16, 1939, now Patent 2,228,448, granted January 14, 1941.

In Letters Patent of the United States, No. 2,015,194, granted on September 24, 1935, to one Max Ruping, a resilient rail fastener is illus-' trated and described. Such rail fastener consists in an elongate shank continued at one end in a resilient crook-shaped head, with the head and the shank centered in a common plane. The device is of compound or bipartite structure; it is formed of two parallel limbs of spring steel, integrated at one end, and pressed in surface-to-surface contact into the form of the fastener. In service the shank is anchored in the body of a rail-tie or sleeper, with the tip of the crook-shaped head pressed in rail-securing engagement upon the basal flange-of the rail borne by the sleeper.

In order to obtain greater efiiciency in particular installations, it has recently been proposed to construct the fastener in more refined or elaborated form; that is, to construct the fastener with its crook-shaped head canted and twisted in its extent from the shank.

More particularly, the invention consists in apparatus that is specifically, though not exclusively, designed for the economical production of such elaborated rail fastener.

In the accompanying drawings Fig. I is a view in side elevation, and Fig. II aview in front elevation, of the fastener. Fig. III is a view, partly in vertical section and partly in side elevation of apparatus in which the invention is embodied. Fig. IV is a View, partly in plan from above and partly in horizontal section, of such apparatus. The plane of section of Fig. III is indicated by the line III-III in Fig. IV, and the plane of section of Fig. IV is indicated by the line IV--IV in Fig. III, and in both Figs. III and IV the ap paratus is shown in an initial stage of operation. Figs. V and VI are views comparable respectively with Figs. III and IV, illustrating the apparatus in a more advanced stage of operation. Fig. VII is a sectional View of the lower portion of the apparatus, as seen on thevertical plane VIIVII of Fig. V, and Fig. VIII is a view of the same portion of the apparatus, as seen on the broken horizontal plane VIII--VIII of Fig. V.

Fig. IX is a View comparable with Figs. III and.

V, illustrating the apparatus in the final stage ture.

of operation. And Fig. X is a fragmentary sectional view of the apparatus, on the plane X-X of Fig. VIII, illustrating means (not elsewhere shown in the drawings) for operating one of the die members of the apparatus.

Referring to Figs. I and II, the reference numeral l is applied to the shank and 2 to the head of the rail fastener. The device, though integrally formed, is of laminar or bipartite struc- More specifically, the fastener is formed from an U-shaped blank B (Figs. III and IV), rounded atone end, with the two legs of the U of substantially equal length, parallel, and centered in common plane. consists in a strap of spring steel medially folded into the form of an U. In the finished article the two limbs of the U extend in surface-to-surface contact. The folded end of the blank forms the shank I of the device, while the opposite bipartite end, fashioned into the form of a Shepherds crook, forms the head 2. As mentioned above, and as may be perceived. in the drawings,

; that inservice bears. immediately upon the flange of the rail to be secured) inclined to a plane P normal to the axis of the shank l.- Typically, the angle (a) of such inclination is 14.

In the manufacture of the above-described rail fastener, the outer or free ends of the legs of the U-shaped blank are bent to a position of angularity with respect to the plane of the U, and the so bent-aside ends of the legs are brought into surface-to-surface contact and shaped into the form of the crook-shaped head 2,. More specifically, and as will presently more fully appear, the free, angularly extending ends of the legs are bent, relatively to the united ends, and swung through a path that extends in, and circumferentially of, a conical surface, and in the course of such operation the said free ends of In this casethe blank.

ends of the legs have thus been shaped into a crook, the folded end of the blank is closed; that is, the united ends of the legs of the U are pressed together and formed into a shank. Thus, the rail fastener is produced, with its crookshaped head 2 canted and twisted in its extent from the shank I.

Turning to Figs. III to X, the apparatus of the invention will be described. The apparatus consists essentially in a set of metal-shaping instrumentalities that may be organized in a press, or a bulldozer, or a bolt-heading or upsetting machine, or other such machine.

Such instrumentalities include a femal die 4 and a male die 5. The female die is rigidly mounted upon a base 6 that may comprise, or may be secured to, the stationary bed or head of a machine (not shown) of the sort alluded to, and the male die is borne upon two or more posts I carried telescopically by head 8, that may comprise, or may be secured to, the powerfully reciprocated head of such machine. In service the male die is reciprocated relatively to the female die, into and from metal-shaping position, and in the course of such reciprocation the head 8 travels through a greater range than the die carried thereby. That is to say, the male die 5 is normally spaced at an interval from the head 8, with springs 9 arranged between, and in the downward stroke of the reciprocating parts the die 5 closes upon the die 4 (i. e. upon a blank in the die 4) and comes to rest, while the head 8 continues in its descent, against the resistance of springs 9, and, coming to abutment upon the male die 5, forces such die into ultimate blankshaping position. The relative movement of the parts is reversed during the upstroke of the head.

The female die includes two die blocks 4a and 4b, which together form a work-receiving matrix M that has a floor 4c and two plan side walls 411 and 4e. The matrix side wall 4d is formed in the block 4b, while the matrix floor 4c and side wall 46 are formed in the block 4a, and the two blocks are relatively movable, such that the matrix M may be alternately widened, to receive a blank B (of. Fig. IV), and narrowed, to engage the blank (cf, Fig. VI). More specifically, the block 4a is rigid with the base 6; the block 417 is secured to the base in a tongue-and-groove engagement I0; and block 4b is slidable in the groove relatively to block 411. The advance of block 4?) into blank-engaging position may be effected by any suitable means, say by a cam II (Fig. X) mounted for rotary movement in suitable bearings (not shown) on the base 6. Integral with the cam an arm I2 may be provided, and such arm may be engaged, as shown, by a vertical bar I3 carried by the reciprocating head 8. During the descent of the head the cam is rotated counterclockwise (Fig. X), and in manifest way it shifts block 4b towards block 4a and closes the matrix upon the blank introduced thereto. Upon the rise of the head 8, and the consequent clockwise rotation of the cam, a spring I4, arranged between the blocks, shifts block 4b away from block 4a and opens the matrix.

Integral with the die-block 4a is a portion 41 that extends outward and downward from the matrix M. The side face ML of such portion provides, above the horizontal plane of the matrix floor 40, an angular continuation of the side face 4c of the matrix, the degree of angularity being indicated at c in Fig. IV. Below such horizontal plane, this angularly extending side face 471. is continued downward and inward to the vertical edge 4k: of the block 4a, which edge, as shown in Figs. III and VII, is contoured to the curvature of the crook-shaped head of the rail fastener I, 2, and is canted with respect to the matrix M, to the same degree that the head of the rail fastener is canted to the shank. The face 4h of the die portion 4) is of concave, conical form. More specifically, the face 471. comprises, substantially, a quarter segment of the side surface of a cone, whose axis is indicated at A--A, Fig, IV, and as presently will appear such face operates as a guide, defining or establishing the path through which the free ends of the blank are benta spiral path that extends upon, and circumferentially of, the conical surface 4h.

The means for bending the legs of the blank consist in an auxiliary die block I5 having a contoured face I 570 complementary in form to the contoured edge 47a of block 4a, and adapted to cooperate therewith in forming the head 2 of the rail fastener. The auxiliary die I5 is secured to and between a pair of radial arms I6. The arms I6 are arranged astraddle the die assembly 4, 5; the arms are provided with journals II that are rotatable on the cone axis A--A, in bearings I8 fixed to base 6. On each journal a segmental gear I9 is secured, and meshing with each gear is gear-rack 20, carried by the reciprocating head 8.

When the head 8 is at the upper limit of its range of reciprocation the dies 4 and 5 are spread and the matrix M is open, as shown in Fig. IV, and the auxiliary die I5 and its associate parts are in the positions illustrated in Fig. III. Then it is that a blank B is introduced to the matrix, it being noted that the folded or closed end of the blank is positioned in the matrix, with the opposite, bipartite end of the blank extending outward from the matrix adjacent to the conical face 4h of the die portion 4 As in the course of its reciprocation the head 8 descends, the die block 4b closes laterally, while the male die moves downward upon the blank, and the auxiliary die I5 swings in clockwise direction (Fig. III) towards engagement with the projecting legs of the blank. The die block 4b, in its matrix-closing movement, presses the blank B against the surfaces 4e and 4h, with the consequence and effect that the outer or free ends of the legs of the blank are (as shown in Fig. VI) bent from the plane in which such legs were initially centered. The descent of the head continues unabated, and, while the male die 5 under spring tension clamps the folded end of the blank in the matrix, the auxiliary die I5 comes to engagement with the projecting ends of the blank. The rotating die I5 closes the engaged ends of the blank upon one another (Fig. V), and, while securing such ends in contact with the conical guiding surface 4h, bends and shapes them under the pressure of the contoured face I5k of the die I5 against the contoured edge Me of die block 4a into the crookshaped head 2, as shown in Fig. IX. Each gearrack 20 includes a shoulder 20a, and, as the die I5 approaches its ultimate position or stage of operation, the shoulders 20a on the gear-racks come to bear upon the edges I 9a of the segmental gears, and, relieving strain on the gear teeth, powerfully press the die I5 to its said ultimate position. Simultaneously, the descending head 8 closes upon the male die 5, forcing such die downward and closing the leg portions of the blank in the matrix into the form of the shank l.

The contoured edge die of the block 4a includes a recess or groove 470, which is of such form that, when the complementary face l5k of the di I5 is, by the engagement of the descending shoulders 28a with the gears l9, pressed home and the blank powerfully shaped against the said edge 4k, not only is the canted crookshaped head formed, but the desired twist is given to the tip of the crock.

It is noteworthy that the rail fastener may by virtue of the apparatus described be produced in a single stroke of the head 8; economy and speed of production are realized; accuracy in structural detail is obtained; and the two legs or limbs of spring steel, forming the body of the finished article, are secured in the desired surface-to-surface contact-a condition difiicult to obtain in the manufacture of such bipartite and resilient articles.

It may be noted that the die-block 4b, is sliding powerfully into blank-securing position with respect to die-block 50., serves to align the two legs of the blank, and also serves to prevent the formation of lateral bulges at the folded end of the blankthe end that forms the blunt point of the shank of the rail fastener. It will also be noted that the die-block 5 and the floor of the matrix M may be particularly fashioned, as at 59, to taper the pointed end of the shank.

The upstroke or return stroke of the head 8, completing the press cylcle, raises the die 5, swings the die l5 back to its starting position, and permits the spring I4 to open die-block 4b relatively to block 4a. The completely formed rail fastener is thus freed, so that it may be ejected by sliding a new blank endwise (in leftto-right direction, Fig. IV) into the open matrix. The apparatus is then ready to repeat the operations described.

I claim as my invention:

1. In apparatus of the class described comprising a female die-block including a matrix, said die-block including a guiding surface that extends angularly from said matrix and forms in effect a continuation of a wall of said matrix, a head reciprocable relatively to said die-block, a spring-backed male die carried by said head and adapted to clamp an elongate blank in said matrix, with one end of the blank extended in position against said angularly extending guiding surface, a die-member mounted for rotation relatively to said female die-block, a gear assembled with said rotary die-member, a gearrack carried by said head and adapted, as said head moves towards said female die-block, to rotate said die-member, with the effect that the extending end of said blank is bent, while guided by said guiding surface, to a crook.

2. In apparatus of the class described comprising a female die-block including a matrix, said die-block including a guiding surface that extends angularly from said matrix and forms in effect a continuation of a wall of said matrix, a head reciprocable relatively to said die-block, an auxiliary die-block movable relatively to said female die-block for laterally pressing an elongate blank against both said wall of the matrix and said angularly extending guiding surface, a spring-backed male di carried by said head and adapted to clamp said elongate blank in said matrix, with one end of the blank extended in position against said angularly extending guiding surface, a die-member mounted for rotation relatively to said female die-block, a gear assembled with said rotary di e-member, a gearrack carried by said head and adapted, as said head moves towards said female die-block, to rotate said die-member, with the effect that the extending end of said blank is bent, while guided by said guiding surface, to a crook.

3. In apparatus of the class described comprising a female die-block including a matrix, said die-block including a guiding surface that extends angularly from said matrix and forms in effect a continuation of a wall of said matrix, a head reciprocable relatively to said die-b1ock, an auxiliary die-block movable relatively to said female die-block for laterally pressing an elongate blank against both said wall of the matrix and said angularly extending guiding surface, a spring-backed male die carried by said head and adapted to clamp said elongate blank in said matrix, with one end of the blank extended in position against said angularly extending guiding surface, a die-member mounted for rotation relatively to said female die-block, and means carried by said head for notating said diemember and bending the angularly extending end of said blank in contact with said guiding surface, said female die-block includes a contoured face adapted to cooperate with said rotary die-member in shaping the so-bent end of the blank.

4. Apparatus of the class described including means for clamping an elongate blank at one end, and means for bending and shaping the opposite end of the blank, said last means including a die-member mounted for rotation relatively to the first-mentioned means, a gear integrated with such die-member, a toothed member in mesh with said gear, and means for shifting said toothed member, with the effect that said gear is rotated and said die-member is powerfully moved through a blank-shaping range of rotation, said toothed member including an abutment and said gear including a portion engaged by said abutment when said die-member approaches ultimate blank-shaping position, to safeguard the teeth of the gear from harmful stress.

5. Metal-shaping apparatus including a die having a matrix that includes a floor and a side wall, said side wall comprising two portions which, as viewed from above the floor, extend angularly to one another, said die including a contoured portion that extends downward from said floor, means for pressing a blank introduced to said matrix against said side wall, to shape the blank to the angularity of the two side wall portions, means for clamping the blank at one end to said floor of the matrix, and a powerfully operated die for bending the extending end of the blank and shaping it against said contoured portion of the die.

6. Metal-shaping apparatus including a die having a matrix with a floor and opposite, relatively movable side walls, a contoured metalshaping portion extending downward from such floor portion, a device for closing the side walls of the matrix upon an elongate blank, a device for clamping one end of the blank to said floor portion of the matrix, a device for bending the opposite end of said blank and shaping it to said contoured portion of the die, and powerfully o-perated means for successively actuating said devices in the-order in which they are above defined.

7. Metal-shaping apparatus including a die block having a matrix that includes a floor and a side wall, a contoured metal-shaping portion extending downward from said floor portion, a guide portion extending outward from said block and including a conical guiding surface that extends upward from one side of said contoured portion to said side wall, a device for clamping one end of a blank to said floor portion, a device for bending the opposite end of the blank downward, while in contact with said guiding surface, and shaping the bend to said contoured portion of the die, and powerfully operated means for successively actuating said devices in the order in which they are above defined.

8. Metal-shaping apparatus including a die having a matrix with a floor portion and opposite, relatively movable side walls, a contoured metal-shaping portion extending downward from such floor portion, means for closing the side walls of the matrix upon an elongate blank, means for clamping one end of the blank to said floor portion of the matrix, and means for bending the opposite end of said blank and shaping it to said contoured portion of the die, one of said side walls of said matrix including two portions extending angularly to one another, with the effect that when said side Walls are closed upon the blank, one end of the blank is shaped to extend angularly to the opposite end.

WILLIAM L. FADER, JR. 

